TECHNICAL FIELD
[0001] The present invention relates to an organic light emitting device comprising an anode
buffer layer using a self doped polymer according to claim 1.
BACKGROUND ART
[0002] Typical structure of conventional organic polymer light emitting devices is such
that an anode (transparent), an anode buffer layer, a light emitting layer, and a
cathode are formed in this order on a transparent substrate. The anode buffer layer
is inserted to make the anode surface flat, thereby preventing electrical short circuit,
and to buffer the injection barrier for the hole injection from the light emitting
layer to the anode.
[0003] A conductive polymer material comprising a mixture of a poly(3,4-ethylenedioxythiophene)
(PEDOT) and a polystyrene sulfonate (PSS) iswidelyusedintheanodebuffer layer. However,
the anode buffer layer using the mixture is disadvantageous in that the polystyrene
sulfonate is contained as an extrinsic dopant and penetrates into the light emitting
layer to deteriorate the light emitting layer.
[0004] With respect to the problem caused by the extrinsic dopant in the anode buffer layer,
a method of using a self-doping conductive polymer in an anode buffer layer without
the extrinsic dopant is disclosed in
JP-T-2003-509816 (
WO01/018888). In this document, polyanilines, polyphenylenevinylenes, polythiophenes, polyisothianaphthenes,poly
(p-phenylene)s,etc. are illustrated as preferred intrinsic conductive polymers capable
of forming a backbone of the self-doping conductive polymer. Further, in this document,
preferred self-doping conductive polymers include self-doping polyanilines, self-doping
polypyrroles, and self-doping polythiophenes, and self-doping sulfonated polyanilines
are described as the most preferred ones with reference to embodiments and Examples.
[0005] The use of a conductive microgel comprising self-doped sulfonated isothianaphthene
polymer having a pH value of 3 to 7 to obtain antistatic articles is disclosed in
JP 10 140141 A. International application
WO87/05914 discloses self-doped conducting polymers having along its backbone a π-electron conjugated
system which comprises a plurality of monomer units, said units having linked thereto
at least one Bronsted acid group.
DISCLOSURE OF THE INVENTION
[0006] As describe above, to overcome the problem of the deterioration of the light emitting
layer due to the extrinsic dopant in the conventional anode buffer layers, the anode
buffer layer using the self-doping sulfonated polyaniline is proposed in
JP-T-2003-509816(
WO01/018888). However, the conductivity of the polyaniline is approximately 10
-1 to 10
-3 S/cm and insufficient for the anode buffer layer, and the polyaniline shows a sufficient
conductivity only in a case where an aqueous coating solution of the polyaniline has
a high acidity (a pH value of 3 or less).
[0007] Further, embodiments of the other preferred conductive polymers are not described
in the above document at all. Thus, though the self-doping conductive polymers has
been proposed in order to solve the problem of the light emitting layer deterioration
due to the extrinsic dopant in the anode buffer layer, there are no self-doping conductive
polymers that can be practically used in the device.
[0008] Accordingly, an object of the present invention is to overcome the problem of the
anode buffer layer in the organic polymer light emitting devices, thereby providing
a self-doping conductive polymer material that can be practically used in an anode
buffer layer, and an organic light emitting device using the same.
[0009] As a result of various research in view of the above object, the inventors have found
that properties of organic light emitting devices can be improved by using an anode
buffer layer comprising a self-doping conductive polymer material showing a low acidity
in form of an aqueous solution. The present invention has been accomplished by this
finding.
[0010] Thus, the invention relates to a polymer for anode buffer layer in an organic light
emitting device, a coating solution for anode buffer layer comprising the polymer,
and an organic light emitting device comprising the anode buffer layer as defined
in claim 1.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011]
Fig. 1 is a cross-sectional view showing an example of an organic light emitting device
of the present invention.
Fig. 2 shows examples of the structure of a non-conjugated phosphorescent polymers
useful in the organic light emitting device of the invention.
DETAILED DESCRIPTION OF INVENTION
[0012] An embodiment of the present invention is described below specifically with reference
to drawings.
[0013] Fig. 1 is a cross-sectional view showing an example of structure of the organic light
emitting device according to the invention, and the structure is such that an anode
buffer layer (3) and a light emitting layer (4) are subsequently formed between an
anode (2) and a cathode(5) disposed on a transparent substrate (1). The structure
of the organic light emitting device of the invention is not limited to the example
of Fig. 1, and may subsequently comprise, between an anode and a cathode, 1) an anode
buffer layer, a hole transporting layer, and a light emitting layer, 2) an anode buffer
layer, a light emitting layer, and an electron transporting layer, 3) an anode buffer
layer, a hole transporting layer, a light emitting layer, and an electron transporting
layer, 4) an anode buffer layer and a layer containing a hole transporting material,
a light emitting material and an electron transporting material, 5) an anode buffer
layer and a layer containing a hole transporting material and a light emitting material,
or 6) an anode buffer layer and a layer containing a light emitting material and an
electron transporting material. Further, though the structure shown in Fig. 1 has
one light emitting layer, the organic light emitting device of the invention may have
two or more light emitting layers.
[0014] According to a first aspect of the invention, there is provided a polymer for the
anode buffer layer, which is a self-doping conductive polymer having a pH value of
3 to 7 in a 1% by mass aqueous solution.
[0015] The 1% by mass aqueous solution of the self-doping conductive polymer further preferably
has a pH value of 4 to 6.
[0016] For example, the anode buffer polymer according to the first aspect of the invention
is preferably a polymer comprising a monomer unit represented by the following formula
(1) :

[wherein M
+ represents a hydrogen ion, an alkali metal ion, or a quaternary ammonium ion, and
k represents 1 or 2], and/or a monomer unit, which is provided by electrochemically
doping the monomer unit of the formula (1), represented by the following formula (2):

[wherein k represents 1 or 2, and +k represents a positive charge number].
[0017] The monomer units represented by the formulae (1) and (2) have one or two sulfonic
acid groups, which may be bonded to any one of the 4-, 5-, 6-, and 7-positions.
[0018] In the formula (1), M
+ represents a hydrogen ion, an alkali metal ion, or a quaternary ammonium ion, and
the monomer unit may contain two or more different cations selected therefrom.
[0019] Examples of the alkali metal ions include Na
+, Li
+, and K
+.
[0020] The quaternary ammonium ion is represented by N(R
1) (R
2)(R
3)(R
4)
+. R
1 to R
4 independently represent a hydrogen atom, a linear or branched, substituted or non-substituted
alkyl group having 1 to 30 carbon atoms, or a substituted or non-substituted aryl
group. The alkyl and aryl groups may contain a group with an atom other than carbon
and hydrogen atoms, such as an alkoxy group, a hydroxyl group, an oxyalkylene group,
a thioalkylene group, an azo group, an azobenzene group, and a p-diphenyleneoxy group.
[0021] Examples of quaternary ammonium cation represented by N(R
1)(R
2)(R
3)(R
4)
+ include a non-substituted, alkyl-substituted, or aryl-substituted cation such as
NH
4+, NH(CH
3)
3+, NH(C
6H
5)
3+, and N(CH
3)
2(CH
2OH)(CH
2-Z)
+. (Z represents a substituent having a chemical formula weight of 600 or less, such
as a phenoxy group, a p-diphenyleneoxy group, a p-alkoxydiphenyleneoxy group, and
a p-alkoxyphenylazophenoxy group.) The cation can be converted to a specific one by
using a common ion exchange resin.
[0022] The alkyl group of R
1 to R
4 may contain a carbonyl bond, an ether bond, an ester bond, an amide bond, a sulfide
bond, a sulfinyl bond, a sulfonyl bond, an imino bond, etc. optionally in the chain.
[0023] The monomer unit represented by the formula (2) can be provided by subjecting the
monomer unit represented by the formula (1) to an electrochemical oxidation doping.
The monomer unit represented by the formula (2) is in the self-doped state, and is
kept electrically neutral by the +k charge delocalized in the aromatic ring and the
main chain and by the -k charge of the sulfonic acid group.
[0024] The monomer units represented by the formula (1) and (2) may have a substituent.
The substituent may be bonded to any one of the 4-, 5-, 6-, and 7-positions except
for a position having the sulfonic acid group. The monomer units may have the same
or different substituents.
[0025] Specific examples of the substituents include linear or branched, saturated or unsaturated
alkyl groups having 1 to 20 carbon atoms, linear or branched, saturated or unsaturated
alkoxy groups having 1 to 20 carbon atoms, a hydroxyl group, halogen atoms, a nitro
group, a cyano group, trihalomethyl groups, a phenyl group, and substituted phenyl
groups. The alkyl groups and the alkoxy groups may contain a carbonyl bond, an ether
bond, an ester bond, a sulfonate bond, an amide bond, a sulfonamide bond, a sulfide
bond, a sulfinyl bond, a sulfonyl bond, an imino bond, or a thioether bond, optionally
in the chain.
[0026] Preferred examples of the monomer units represented by the formulae (1) or (2) include
5-sulfoisothianaphthene-1,3-diyl, 4-sulfoisothianaphthene-1,3-diyl, 4-methyl-5-sulfoisothianaphthene-1,3-diyl,
6-methyl-5-sulfoisothianaphthene-1,3-diyl, 6-methyl-4-sulfoisothianaphthene-1,3-diyl,
5-methyl-4-sulfoisothianaphthene-1,3-diyl, 6-ethyl-5-sulfoisothianaphthene-1,3-diyl,
6-propyl-5-sulfoisothianaphthene-1,3-diyl, 6-butyl-5-sulfoisothianaphthene-1,3-diyl,
6-hexyl-5-sulfoisothianaphthene-1,3-diyl, 6-decyl-5-sulfoisothianaphthene-1,3-diyl,
6-methoxy-5-sulfoisothianaphthene-1,3-diyl, 6-ethoxy-5-sulfoisothianaphthene-1,3-diyl,
6-chloro-5-sulfoisothianaphthene-1,3-diyl, 6-bromo-5-sulfoisothianaphthene-1,3-diyl,
6-trifluoromethyl-5-sulfoisothianaphthene-1,3-diyl, salts thereof such as lithium
salts, sodium salts, ammonium salts, methylammonium salts, ethylammonium salts, dimethylammonium
salts, diethylammonium salts, trimethylammonium salts, triethylammonium salts, tetramethylammonium
salts, and tetraethylammonium salts, etc.
[0027] The polymer for the anode buffer layer may be a homopolymer comprising one type of
the monomer unit represented by the formula (1) or (2), a copolymer comprising two
or more types of the monomer units represented by the formula (1) or (2), or a copolymer
comprising one or more types of the monomer units represented by the formula (1) or
(2) and one or more types of π-electron conjugated monomer units having no sulfonic
acid groups.
[0028] Examples of the π-electron conjugated monomer units having no sulfonic acid groups
include vinylene, isothianaphthenylene, isobenzofurylene, isobenzoindolylene, thienylene,
pyrrolylene, furylene, iminophenylene and phenylene. More than one types of the monomer
units among these may be contained.
[0029] The polymer for the anode buffer layer has a sulfonic acid group, and thereby has
water solubility. As the anode buffer polymer has more sulfonic acid groups, the water
solubility is increased. Since most of currently-usable light emitting polymer materials
are organic solvent-soluble and water-insoluble, the anode buffer polymer, whichiswater-soluble
and organic solvent-insoluble, is extremely advantageous in that the anode buffer
layer can be laminated with the light emitting layer by a coating process to produce
the organic light emitting device.
[0030] In a case where polymer for the anode buffer layer is a copolymer comprising one
or more types of the monomer units represented by the formula (1) or (2) and one or
more types of the π-electron conjugated monomer units having no sulfonic acid groups,
the total mole fraction of the monomer units represented by the formula (1) or (2)
to the anode buffer polymer is preferably 0.2 to 1, more preferably 0.5 to 1.
[0031] The polymer for the anode buffer layer comprises the monomer unit represented by
the formula (1) and/or the monomer unit represented by the formula (2). When the content
of the self-doped monomer unit represented by the formula (2) is higher, the conductivity
of the anode buffer polymer is higher and holes can be injected at a lower voltage,
whereby the driving voltage of the device can be reduced. Even in a case where the
polymer for the anode buffer layer comprising only the monomer unit represented by
the formula (1) without the monomer unit represented by the formula (2) is practically
used in the organic light emitting device, holes are injected from the anode to the
anode buffer layer by applying electrical power, so that the monomer unit represented
by the formula (1) in the anode buffer layer may be oxidized into the doped state
and thus converted to the monomer unit represented by the formula (2). Thus, also
the polymer comprising only the monomer unit represented by the formula (1) can be
used for the anode buffer layer in the invention. The polymer comprising the monomer
unit represented by the formula (1) and/or the monomer unit represented by the formula
(2) can be used for the anode buffer layer in the invention without particular restrictions.
[0032] The weight average molecular weight of the self-doping polymer used in the invention
is preferably within the range of 1,000 to 200,000, more preferably within the range
of 5,000 to 100,000.
[0033] Particularly preferred examples of the self-doping polymers include 5-sulfoisothianaphthene-1,3-diyl
polymers, random copolymers containing 80 mol% or more of 5-sulfoisothianaphthene-1,3-diyl,
poly(5-sulfoisothianaphthene-1,3-diyl-co-isothianaphthene-1, 3-diyl), salts thereof
such as lithium salts, sodium salts, ammonium salts, and triethylammonium salts, etc.
[0034] Among the polymer for the anode buffer layer poly(isothianaphthenesulfonic acid)s,
which are the homopolymers of the monomer unit represented by the formula (1) or (2),
have a smaller semiconductor bandgap of approximately 1. 0 eV, show the conductivity
at a lower doping level, and achieve a more stable conducting, as compared with the
other known sulfonic acid-containing conductive polymers such as polythiophene derivatives
and polyaniline derivatives having an alkanesulfonic acid group. Thus, the homopolymers
have a smaller visible light absorbance particularly in the doped state, and thereby
can form a transparent anode buffer layer excellent in stability.
[0035] The polymer comprising the monomer unit represented by the formula (1) and/or the
monomer unit represented by the formula (2), and the copolymer comprising one or more
types of the monomer units represented by the formula (1) or (2) and one or more types
of π-electron conjugated monomer units having no sulfonic acid groups can be produced
according to methods disclosed in
JP-A-6-49183 and
JP-A-7-48438. By the methods, the polymer comprising the monomer unit represented by the formula
(1) and/or the monomer unit represented by the formula (2) can be produced by reacting
a compound represented by the following formula (3) or (4) with a sulfonating agent
such as fuming sulfuric acid.

[wherein a hydrogen atom in the aromatic ring may be replaced by a substituent.]

[wherein a hydrogen atom in the aromatic ring may be replaced by a substituent.]
[0036] In formula (3) and (4), examples of substituent on the aromatic ring include alkyl
groups having 1 to 10 carbon atoms (such as methyl, ethyl, propyl, butyl, hexyl and
decyl), alkoxy groups having 1 to 4 carbon atoms (such as methoxy and ethoxy), and
halogen atoms (such as fluorine, chlorine and bromine). The above alkyl group or an
alkyl group in the above alkoxy group may be substituted by a halogen atom.
[0037] Specifically, by reacting the compound represented by the formula (3) or (4) with
the sulfonating agent, cationic polymerization and sulfonation proceed in one reaction
liquid, so that a copolymer comprising the monomer unit represented by the formula
(1) (in which M
+ is H
+) and the monomer unit represented by the formula (2) is generated first. The copolymer
is neutralized by an alkali such as sodium hydroxide and ammonium hydroxide. In the
neutralization, the pH value adjusted is preferably 3 to 7, more preferably 4 to 6.
The sulfonic acid moieties of the polymerization product may be converted to H type
moieties by ion exchange, and then may be neutralized by the alkali such as sodium
hydroxide and ammonium hydroxide. Also in the neutralization, the pH value adjusted
is preferably 3 to 7, more preferably 4 to 6. The polymer for the anode buffer layer
of the invention can be obtained by evaporating water from the neutralized solution.
[0038] A second aspect of the invention pertains to an anode buffer layer coating solution
containing the polymer for the anode buffer layer according to the first aspect.
[0039] The polymer for the anode buffer layer is water-soluble, and the solvent for the
anode buffer layer coating solution is preferably water. In the anode buffer layer
coating solution, the content of the anode buffer polymer is preferably 0.1 to 10%
by mass, more preferably 0.5 to 5% by mass.
[0040] The anode buffer layer coating solution may contain a surfactant to improve the wettability
to the substrate. Examples of the surfactants usable in the invention include anionic
surfactants such as carboxylate salts, α-olefin sulfonate salts, alkylbenzene sulfonate
salts, alkyl sulfonate salts, alkyl ether sulfonate ester salts, and alkylsulfonate
triethanolamines; cationic surfactants such as alkyltrimethylammonium salts, dialkyldimethylammonium
chlorides, and alkylpyridinium chlorides; ampholytic surfactants such as alkylcarboxybetaines;
nonionic surfactants such as carboxylic diethanolamides, polyoxyethylene alkyl ethers,
and polyoxyethylene alkyl phenyl ethers; etc. The ratio of the surfactant to the polymer
for the anode buffer layer of the invention is preferably 100% by mass or less, more
preferably 30% by mass or less.
[0041] The anode buffer layer coating solution may contain also a high-polar alcohol such
as methanol, ethanol, and 2-propanol, to improve the wettability to the substrate.
The ratio of the alcohol to the entire anode buffer layer coating aqueous solution
is preferably 60% by mass or less.
[0042] The anode buffer layer coating solution may further contain various additives needed
in a film forming process such as a spin coating method, an ink-jet method, and a
printing method, and examples of the additives include thickeners, dispersing agents,
antifoaming agents, antioxidants, light stabilizers, and lubricants.
[0043] According to an embodiment of the invention, there is provided an organic light emitting
device having the anode buffer layer containing the polymer for the anode buffer layer
according to the first aspect.
[0044] The anode buffer layer of the organic light emitting device of the invention may
be formed by applying the anode buffer layer coating solution according to the second
aspect onto the substrate provided with the anode, and by drying the solution to remove
the solvent. The coating solution may be applied by a spin coating method, an ink-jet
method, a printing method, a spray method, a dispenser method, etc. The thickness
of the anode buffer layer is preferably 10 to 200 nm, more preferably 20 to 100 nm.
[0045] In the organic light emitting device of the invention, each compound used in the
light emitting layer, the hole transporting layer, and the electron transporting layer
may be a low or high molecular weight compound. High molecular weight compounds are
preferably used to simplify the processes for producing the device because the anode
buffer layer comprises the polymer compound.
[0046] Examples of the light emitting materials for forming the light emitting layer of
the organic light emitting device of the invention include low molecular weight light
emitting materials and high molecular weight light emitting materials described in
Yutaka Ohmori, Oyo Buturi, Vol. 70, No. 12, Page 1419-1425 (2001), etc. Among the light emitting materials, particularly phosphorescent materials
are preferred from the viewpoint of high light emitting efficiency. Further, light
emitting polymer materials are preferred from the viewpoint of simplifying the processes
for producing the device. Thus, phosphorescent polymer compounds are more preferred.
[0047] The structure of the phosphorescent polymer compound used for the light emitting
layer in the organic light emitting device is not particularly restricted as long
as the compound can emit phosphorescence at room temperature. A first example of the
polymer structure of the phosphorescent polymer compound is such that a skeleton of
a conjugated polymer such as a poly(p-phenylene), a poly(p-phenylenevinylene), a polyfluorene,
a polythiophene, a polyaniline, a polypyrrole, and a polypyridine is bonded with a
phosphorescent moiety. (The phosphorescent moiety may be typically a mono- or di-valent
group of a complex of transition metal or rare earth metal to be hereinafter described.)
In the polymer structure, the phosphorescent moiety may be contained in the main chain
or the side chain.
[0048] Another example of the polymer structure of the phosphorescent polymer compound is
such that a skeleton of a non-conjugated polymer such as a polyvinylcarbazole and
a polysilane is bonded with the phosphorescent moiety. In the polymer structure, the
phosphorescent moiety may be contained in the main chain or the side chain.
[0049] Further example of the structure of the phosphorescent polymer compound is a dendrimer
having the phosphorescent moiety. In the structure, the phosphorescent moiety may
be contained in the core, branched part, or end of the dendrimer.
[0050] In above structures of the polymer compound, phosphorescence is emitted from the
phosphorescent moiety connected to the conjugated or non-conjugated skeleton. The
polymer compound may be such that phosphorescence is emitted from the conjugated or
non-conjugated skeleton. It is preferred that the phosphorescent polymer compound
for the organic light emitting device of the invention is a polymer comprising the
non-conj ugated skeleton with the phosphorescent moiety (hereinafter referred to as
a non-conjugated phosphorescent polymer), because such a polymer is flexible in material
design, phosphorescence can be relatively easily obtained from the polymer, the polymer
can be easily synthesized, the polymer has a high solubility in solvents, and thereby
the coating solution can be easily prepared.
[0051] The non-conjugated phosphorescent polymer described above comprises the phosphorescent
moiety and a carrier transporting moiety. As shown in Fig. 2, typical examples of
the polymer structure containing connection between phosphorescent moiety and a carrier
transporting moiety include (1) a structure where both of the phosphorescent moiety
and the carrier transporting moiety are contained in the polymer main chain, (2) a
structure where the phosphorescent moiety is contained in the polymer side chain and
the carrier transporting moiety is contained in the polymer main chain, (3) a structure
where the phosphorescent moiety is contained in the polymer main chain and the carrier
transporting moiety is contained in the polymer side chain, and (4) a structure where
both of the phosphorescent moiety and the carrier transporting moiety are contained
in the polymer side chain. Further, the polymer may have a cross-linked structure.
[0052] The non-conjugated phosphorescent polymer may have two or more types of the phosphorescent
moieties, which may be contained in the main chain or the side chain respectively.
Further, the polymer may have two or more types of the carrier transporting moieties,
which may be contained in the main chain or the side chain respectively.
[0053] The weight average molecular weight of the non-conjugated phosphorescent polymer
is preferably 1,000 to 100,000, more preferably 5,000 to 50,000.
[0054] A mono-, di-, or poly-valent group of a compound capable of emitting phosphorescence
at room temperature can be used as the phosphorescent moiety. The phosphorescent moiety
is preferably a mono- or di-valent group of a transitionmetal complex or a rare earth
metal complex. The transition metal in the transition metal complex may be a metal
of the first transition element series of Sc with the atomic number 21 to Zn with
the atomic number 30, the second transition element series of Y with the atomic number
39 to Cd with the atomic number 48, or the third transition element series of Hf with
the atomic number 72 to Hg with the atomic number 80, of the Periodic Table of Elements.
The rare earth metal in the rare earth metal complex may be a metal of the lanthanoid
series of La with the atomic number 57 to Lu with the atomic number 71 of the Periodic
Table of Elements.
[0055] The ligands of the transition metal complex and the rare earth metal complex include
those described in
G. Wilkinson (Ed.), Comprehensive Coordination Chemistry, Plenum Press, 1987, and
Akio Yamamoto, Yuki Kinzoku Kagaku Kiso to Oyo, Shokabo Publishing Co., Ltd., 1982. Preferred examples of the ligands include halogen ligands; nitrogen-containing heterocyclic
ligands (such as phenylpyridine ligands, benzoquinoline ligands, quinolinol ligands,
bipyridyl ligands, terpyridine ligands, and phenanthroline ligands) ; diketone ligands
(such as acetylacetone ligands and dipivaloylmethane ligands); carboxylic acid ligands
(such as acetic acid ligands); phosphine ligands (such as triphenylphosphine ligands
and phosphite ester ligands) ; carbon monoxide ligands; isonitrile ligands; and cyano
ligands. A single metal complex may contain several types of the ligands. Further,
each of the metal complexes may be a bi- or poly-nuclear complex.
[0056] The carrier transporting moiety may be a mono-, di-, or poly-valent group of a hole
transporting compound, an electron transporting compound, or a bipolar compound capable
of transporting holes and electrons. Examples of the hole transporting type carrier
transporting moieties include mono- or di-valent groups of carbazole, triphenylamine
and N,N'-diphenyl-N,N'-(3-methylphenyl)-1,1'-biphenyl-4,4'-diami ne (TPD). Examples
of the electron transporting type carrier transporting moieties include mono- or di-valent
groups of quinolinol derivative metal complexes such as tris(quinolinol) aluminum
(Alq
3), oxadiazole derivatives, triazole derivatives, imidazole derivatives and triazine
derivatives. Further, examples of the bipolar carrier transporting moieties include
mono- or di-valent groups of 4,4'-N,N'-dicarbazole-biphenyl (CBP).
[0057] In the organic light emitting device of the invention, the light emitting layer may
comprise only the above-described phosphorescent polymer compound. Further, the light
emitting layer may comprise a composition prepared by mixing the phosphorescent polymer
compound with another carrier transporting compound to complement the carrier transporting
properties of the phosphorescent polymer compound. Thus, the hole transporting type
phosphorescent polymer compound may be combined with an electron transporting compound,
and the electron transporting type phosphorescent polymer compound may be combined
with the hole transporting compound. The carrier transporting compound used in combination
with the phosphorescent polymer compound may be a low or high molecular weight compound.
[0058] Examples of the low molecular weight hole transporting compounds used in combination
with the phosphorescent polymer compound include conventionally known hole transporting
compounds such as triphenylamine derivatives such as N,N'-diphenyl-N,N'-(3-methylphenyl)-1,1'-biphenyl-4,4'-diami
ne (TPD), 4,4'-bis[N-(1-naphthyl)-N-phenylamino]biphenyl (α-NPD), and 4,4',4''-tris(3-methylphenylphenylamino)triphenylamine
(m-MTDATA). Examples of the high molecular weight hole transporting compounds used
in combination with the phosphorescent polymer compound include polyvinylcarbazoles,
polymers produced by introducing a polymerizable functional group into a triphenylamine-based
low molecular weight compound such as polymer compounds with triphenylamine structures
disclosed in
JP-A-8-157575.
[0059] Examples of the low molecular weight electron transporting compounds used in combination
with the phosphorescent polymer compound include quinolinol derivative metal complexes
such as tris(quinolinol) aluminum (Alq
3), oxadiazole derivatives, triazole derivatives, imidazole derivatives and triazine
derivatives. Examples of the high molecular weight electron transporting compounds
used in combination with the phosphorescent polymer compound include polymers produced
by introducing a polymerizable functional group into the above low molecular weight
electron transporting compound such as polyphenylbiphenyloxadiazole(polyPBD) (polyPBD)
disclosed in
JP-A-10-1665.
[0060] Further, to improve the physical properties, etc. of the film of the phosphorescent
polymer compound, a polymer compound having no direct effect on the light emitting
properties of the phosphorescent polymer compound may be added and thus-obtained composition
may be used as the light emitting material. For example, a PMMA (polymethyl methacrylate)
or a polycarbonate may be added to make the resultant film flexible.
[0061] The thickness of the light emitting layer is preferably 1 nm to 1 µm, more preferably
5 nm to 300 nm, further preferably 10 nm to 100 nm.
[0062] In the organic light emitting device of the invention, the hole transportingmaterial
for forming the hole transporting layer may be a known low molecular weight hole transporting
material, and examples thereof include triphenylamine derivatives such as N,N'-dimethyl-N,N'-(3-methylphenyl)-1,1'-biphenyl-4,4'-diami
ne (TPD), 4,9'-bis[N-(1-naphthyl)-N-phenylamino]biphenyl(α-NPD), and 4,4',4''-tris(3-methylphenylphenylamino)triphenylamine
(m-MTDATA), and polyvinylcarbazoles. The hole transporting material may be a high
molecular weight hole transporting materials, and examples thereof include polymers
produced by introducing a polymerizable functional group into a triphenylamine-based
low molecular weight compound such as polymer compounds with a triphenylamine skeleton
disclosed in
JP-A-8-157575, and polymer materials such as poly(para-phenylenevinylene)s and polydialkylfluorene.
These hole transporting materials may be used singly, or mixed or layered with a different
hole transporting material. The thickness of the hole transporting layer is preferably
1 nm to 5 µm, more preferably 5 nm to 1 µm, further preferably 10 nm to 500 nm.
[0063] In the organic light emitting device of the invention, the electron transporting
material for the electron transporting layer may be a known low molecular weight electron
transporting material, and examples thereof include quinolinol derivative metal complexes
such as tris(quinolinol) aluminum (Alq
3), oxadiazole derivatives, triazole derivatives, imidazole derivatives and triazine
derivatives. Further, the electron transporting material may be a high molecular weight
electron transporting material, and examples thereof include polymers produced by
introducing a polymerizable functional group into the above-mentioned low molecular
weight electron transporting compound, such as polyphenylbiphenyloxadiazole(polyPBD)
disclosed in
JP-A-10-1665. These electron transporting materials may be used singly, or mixed or layered with
a different electron transporting material. The thickness of the electron transporting
layer is preferably 1 nm to 5 µm, more preferably 5 nm to 1 µm, further preferably
10 nm to 500 nm.
[0064] Each of the phosphorescent polymer compound for the light emitting layer described
above, the hole transporting material for the hole transporting layer, and the electron
transporting material for the electron transporting layer may be used alone or in
combination with a binder of a polymer material to form each layer. Examples of the
polymer materials for the binder include polymethyl methacrylates, polycarbonates,
polyesters, polysulfones and polyphenylene oxides.
[0065] The light emitting layer, the hole transporting layer, and the electron transporting
layer can be formed by a resistance heating deposition method, an electron beam deposition
method, a sputtering method, an ink-jet method, a spin coating method, a dip coating
method, a printing method, a spray method, a dispenser method, etc. The low molecular
weight compounds are formed into a layer generally by a resistance heating deposition
method or an electron beam deposition method, and the high molecular weight compounds
are formed into a layer generally by an ink-jet method or a spin coating method.
[0066] A hole blocking layer may be formed on the cathode side of the light emitting layer
in order that holes can be prevented from passing through the light emitting layer
to be efficiently recombined with electrons in the light emitting layer. The hole
blocking layer may comprise a compound having a deeper energy level of highest occupied
molecular orbital (HOMO) than that of the light emitting material, and examples there
of include triazole derivatives, oxadiazole derivatives, phenanthroline derivatives
and aluminum complexes.
[0067] An exciton blocking layer may be formed on the cathode side of the light emitting
layer to prevent deactivation of excitons due to the cathode metal. The exciton blocking
layer may comprise a compound having an excited triplet energy larger than that of
the light emitting material, and examples there of include triazole derivatives, phenanthroline
derivatives and aluminum complexes.
[0068] The anode of the organic light emitting device of the invention may comprise a known
transparent conductive material, and examples of the materials include indium tin
oxide (ITO), tin oxide, zinc oxide, and conductive polymers such as polythiophenes,
polypyrroles and polyanilines. The electrode comprising the transparent conductive
material preferably has a surface resistance of 1 to 50 Ω/square (ohm/square). The
materials may be formed into a film by an electron beam deposition method, a sputtering
method, a chemical reaction method, a coating method, etc. The anode preferably has
a thickness of 50 to 300 nm.
[0069] In the organic light emitting device of the invention, the cathode may comprise a
known material having a small work function and chemical stability, and examples of
the materials include Al, Mg-Ag alloys and alloys of Al and alkali metals such as
Al-Li alloys and Al-Ca alloys. It is preferred that the work function of the material
is 2.9 eV or more from the viewpoint of the chemical stability. The cathode can be
formed from the material by a resistance heating deposition method, an electron beam
deposition method, a sputtering method, an ion plating method, etc. The thickness
of the cathode is preferably 10 nmto 1 µm, more preferably 50 to 500 nm.
[0070] A metal layer lower in work function than the cathode may be disposed as a cathode
buffer layer between the cathode and the adjacent organic layer, to buffer the injection
barrier for the electron injection from the cathode to the organic layer, thereby
increasing the electron injection efficiency. Examples of the metals with a lower
work function, which can be used in the cathode buffer layer, include alkali metals
such as Na, K, Rb, and Cs and alkaline earth metals such as Sr and Ba, rare earth
metals such as Pr, Sm, Eu, and Yb. An alloy or a metal compound may be used for the
cathode buffer layer as long as it is lower in work function than the cathode. The
cathode buffer layer may be formed by a vapor deposition method, a sputtering method,
etc. The thickness of the cathode buffer layer is preferably 0.05 to 50 nm, more preferably
0.1 to 20 nm, further preferably 0.5 to 10 nm.
[0071] The cathode buffer layer may comprise a mixture of the above material having a small
work function and an electron transporting material. The electron transporting material
used in the cathode buffer layer may be the above-described organic compound for the
electron transporting layer. In this case, the cathode buffer layermaybe formed by
a codepositionmethod. Further, the cathode buffer layer may be formed from a solution
by a spin coating method, a dip coating method, an ink-jet method, a printing method,
a spray method, a dispenser method, etc. In this case the thickness of the cathode
buffer layer is preferably 0.1 to 100 nm, more preferably 0.5 to 50 nm, further preferably
1 to 20 nm.
[0072] In the organic light emitting device of the invention, the substrate may be an insulating
substrate transparent against the emission wavelength of the light emitting material.
The substrate may comprise a known material of a glass or a transparent plastic such
as PET (polyethylene terephthalate) and polycarbonate.
BEST MODE FOR CARRYING OUT THE INVENTION
[0073] The present invention will be explained in more detail below referring to representative
Synthesis Examples and Examples. The Examples are considered in all respects to be
illustrative, and the invention as defined by the claims is not restricted thereto.
[0074] Measuring apparatuses used in Examples are as follows. Unless otherwise noted, reagents
used in Examples are commercial products (special grade) without purifying them .
- 1) 1H-NMR
JNM EX270 manufactured by JEOL Ltd., 270 MHz
Solvent: Chloroform-d
- 2) Elemental analysis apparatus
CHNS-932 manufactured by LECO Corporation
- 3) GPC measurement (molecular weight measurement)
Column: Shodex KF-G + KF804L + KF802 + KF801
Eluent: Tetrahydrofuran (THF)
Temperature: 40°C
Detector: RI (Shodex RI-71)
- 4) ICP elemental analysis
ICPS 8000 manufactured by Shimadzu Corporation
Synthesis Example 1: Synthesis of polymer for the anode buffer layer, poly(5-sulfoisothianaphthene-1,3-yl)
(hereinafter referred to as polySITN)
[0075] A polymer with H-type sulfonic acid groups was obtained according to a method disclosed
in
JP-A-6-49183, Example 3. 3.5 g of 1 N ammonium hydroxide was added to 100 ml of a 1% by mass aqueous
solution of the obtained polymer, to adjust the pH value to 4.4. Water was evaporated
from the aqueous polymer solution to obtain 0.99 g of a navy blue polymer. The mole
fraction of the self-dopingmonomer corresponding to the formula (2) was 0.21, which
was calculated from the amount of the alkali required for the neutralization. The
polymer had a weight average molecular weight of 17,200, obtained by a GPC measurement
with polystyrene standard.
Synthesis Example 2: Synthesis of phosphorescent monomer, [6-(4-vinylphenyl)-2,4-hexanedionato]-bis(2-phenylpyridine)
iridium (III) (hereinafter referred to as IrPA)
[0076] IrPA was synthesized according to a method disclosed in
JP-A-2003-113246.
Synthesis Example 3: Synthesis of phosphorescent copolymer, poly(N-vinylcarbazole-co-[6-(4-vinylphenyl)-2,4-hexanedionat
o]-bis(2-phenylpyridine) iridium (III)) (hereinafter referred to as poly(VCz-co-IrPA))
[0077] The above copolymer was synthesized as a light emitting material containing a light
emitting moiety of IrPA and a hole transporting moiety of N-vinylcarbazole.
[0078] 1.55 g (8.0 mmol) of N-vinylcarbazole, 29 mg (0.04 mmol) of [6-(4-vinylphenyl)-2,4-hexanedionato]bis
(2-phenylpyridine)iridium (III) (Ir(ppy)
2[1-(StMe)-acac]), and 13 mg (0.08 mmol) of AIBN were dissolved in 40 ml of dry toluene,
and argon was passed therethrough for 1 hour. The resultant solution was heated to
80°C to initiate the polymerization reaction, and then stirred for 8 hours. The reaction
liquid was cooled and added dropwise to 250 ml of methanol, whereby a polymer was
precipitated and isolated by filtration. The isolated polymer was dissolved in 25
ml of chloroform, the resultant solution was added dropwise to 250 ml of methanol,
whereby the polymer was purified by reprecipitation. The polymer was vacuum-dried
at 60°C for 12 hours to obtain 1.14 g of the subject substance poly(VCz-co-IrPA) with
a recovery rate of 72%. The polymer had a number average molecular weight of 4,800
and a weight average molecular weight of 11,900, obtained by a GPC measurement with
polystyrene standard. Further, the polymer had a phosphorescent Ir complex moiety
content of 0. 62 mol% obtained by an ICP elemental analysis.
Synthesis Example 4: Synthesis of electron transporting polymer compound, polyphenylbiphenyloxadiazole
(polyPBD) of formula (5)
[0079]

[0080] A polyPBD was synthesized according to a method disclosed in
JP-A-10-1665. The polyTPD had a number average molecular weight of 32, 400 and a weight average
molecular weight of 139, 100, obtained by a GPC measurement with polystyrene standard.
Example 1: Surface resistance and conductivity of self-doping polyisothianaphthene
film
[0081] A 1% by mass aqueous solution of the polySITN synthesized in Synthesis Example 1
was prepared, applied onto a glass substrate by a spin coater at 3,000 rpm for 60
seconds, and dried at 140°C for 30 minutes. As a result, a film with 30 nm thickness
was obtained. The surface resistance of the film, measured by Megaresta Model HT-301
manufactured by Shishido Electrostatic, Ltd., was 6×10
5 Ω/square. The film had a conductivity of 1.8 S/cm calculated from the surface resistance
value.
Example 2: Production and light emitting properties of organic light emitting device
(fluorescent device) having anode buffer layer of self-doping polyisothianaphthene
[0082] An organic light emitting device was produced using an indium tin oxide(ITO)-having
substrate available from Nippo Electric Co., Ltd. The ITO-having substrate comprised
a 25-mm-square glass substrate and two 4-mm-width ITO electrodes, which were formed
in stripe as an anode on one surface of the glass substrate. Prepared first was a
coating solution for forming an anode buffer layer, which was a 1% by mass aqueous
solution of the polySITN synthesized in Synthesis Example 1. The coating solution
had a pH value of 4.4. The coating solution was applied onto the ITO-having substrate
by a spin coater at 3, 000 rpm for 30 seconds, and dried at 140°C for 30 minutes to
form an anode buffer layer. The obtained anode buffer layer had a thickness of approximately
30 nm. Then, a coating solution for forming a light emitting layer was prepared. That
is, 45 mg of poly(2-methoxy-5-(2'-ethylhexyloxy)-1,4-phenylenevinylene) ADS100RE available
from American Dye Source Inc. (hereinafter referred to as MEH-PPV) was dissolved in
2,955 mg of tetrahydrofuran (special grade, available from Wako Pure Chemical Industries,
Ltd.), and the resulting solution was passed through a filter with a pore size of
0.2 µm to obtain the coating solution. The obtained coating solution was applied onto
the anode buffer layer by a spin coating method at a rotation rate of 3,000 rpm for
an application time of 30 seconds, and dried at 140°C for 30 minutes to form the light
emitting layer. The light emitting layer had a thickness of approximately 100 nm.
Then, the substrate coated with the light emitting layer was placed in a deposition
apparatus, calcium was deposited thereon into a thickness of 25 nm at a deposition
rate of 0.1 nm/s, and aluminum was deposited as a cathode to a thickness of 250 nm
at a deposition rate of 1 nm/s. The calcium layer and the aluminum layer were each
formed into two 3-mm-width stripes perpendicular to the longitudinal direction of
the anode. Lead wires were connected to the anode and the cathode under an argon atmosphere
lastly, so that four 4-mm-long, 3-mm-wide, organic light emitting devices were produced
per one substrate. Each of the organic EL devices was driven by applying voltage using
a programmable direct voltage/current source (TR6143) manufactured by Advantest Corporation,
whereby the luminance was measured by a luminance meter BM-8 manufactured by Topcon
Corporation. As a result, the organic light emitting devices had the maximum luminance,
the maximum external quantum efficiency, and the luminance half-life at an initial
luminance of 100 cd/m
2 shown in Table 1 (as average values of the four devices formed on one substrate).
Example 3: Production and light emitting properties of organic light emitting device
(phosphorescent device) having anode buffer layer of self-doping polyisothianaphthene
[0083] Organic light emitting devices were produced and evaluated on light emitting properties
in the same manner as Example 2 except that a light emitting layer was formed as follows.
63.0 mg of poly(VCz-co-IrPA) synthesized in Synthesis Example 3 and 27.0 mg of polyPBD
synthesized in Synthesis Example 4 were dissolved in 2, 910 mg of toluene (special
grade, available from Wako Pure Chemical Industries, Ltd.), and the resulting solution
was passed through a filter with a pore size of 0.2 µm to obtain a coating solution.
The obtained coating solution was applied onto the anode buffer layer by a spin coater
at 3, 000 rpm for 30 seconds, and dried at 140°C for 30 minutes to form the light
emitting layer. The light emitting layer had a thickness of approximately 80 nm. As
a result, the organic light emitting devices had the maximum luminance, the maximum
external quantum efficiency, and the luminance half-life at an initial luminance of
100 cd/m
2 shown in Table 1 (as average values of the four devices formed on one substrate).
Comparative Example 1: Production and light emitting properties of organic light emitting
device (fluorescent device) having anode buffer layer of mixture of poly(3,4-ethylenedioxythiophene)
and polystyrene sulfonate
[0084] Organic light emitting devices were produced and evaluated on light emitting properties
in the same manner as Example 2 except that an anode buffer layer was formed as follows.
An aqueous solution of a mixture of poly(3,4-ethylenedioxythiophene) and polystyrene
sulfonate, BAYTRON CH8000 (trade name, available from Bayer Co.), was used as a coating
solution for forming the anode buffer layer. The coating solution had a solid content
of 2.8% by mass, and after the coating solution was diluted with water until the solid
content became 1% by mass, the pH value was 2.4. The coating solution was applied
onto the ITO-having substrate by a spin coater at 3,500 rpm for 40 seconds, and dried
at 140°C for 30 minutes to form the anode buffer layer. The anode buffer layer had
a thickness of approximately 50 nm. As a result, the organic light emitting devices
had the maximum luminance and the luminance half-life at an initial luminance of 100
cd/m
2 shown in Table 1 (as average values of the four devices formed on one substrate).
Comparative Example 2: Production and light emitting properties of organic light emitting
device (phosphorescent device) having anode buffer layer of mixture of poly(3,4-ethylenedioxythiophene)
and polystyrene sulfonate
[0085] Organic light emitting devices were produced and evaluated on light emitting properties
in the same manner as Comparative Example 1 except that a light emitting layer was
formed as follows. 63.0 mg of poly(VCz-co-IrPA) synthesized in Synthesis Example 3
and 27.0 mg of polyPBD synthesized in Synthesis Example 4 were dissolved in 2,910
mg of toluene (special grade, available from Wako Pure Chemical Industries, Ltd.),
and the resulting solution was passed through a filter with a pore size of 0.2 µm
to obtain a coating solution. The obtained coating solution was applied onto the anode
buffer layer by a spin coater at 3,000 rpm for 30 seconds, and dried at 140°C for
30 minutes to form the light emitting layer. The light emitting layer had a thickness
of approximately 80 nm. As a result, the organic light emitting devices had the maximum
luminance, the maximum external quantum efficiency, and the luminance half-life at
an initial luminance of 100 cd/m
2 shown in Table 1 (as average values of the four devices formed on one substrate).
Comparative Example 3: Production and light emitting properties of organic light emitting
device (fluorescent device) having anode buffer layer of self-doping polyaniline
[0086] Organic light emitting devices were produced and evaluated on light emitting properties
in the same manner as Example 2 except that an anode buffer layer was formed as follows.
An aqueous solution of poly(aniline sulfonic acid) (hereinafter referred to as polySAN)
available from Sigma-Aldrich Japan K. K. was used as a coating solution for forming
the anode buffer layer. The coating solution had a solid content of 5% by mass, and
after the coating solution was diluted with water until the solid content became 1%
by mass, the pH value was 2.5. The coating solution was applied onto the ITO-having
substrate by a spin coater at 5,000 rpm for 30 seconds, and dried at 140°C for 30
minutes to form the anode buffer layer. The anode buffer layer had a thickness of
approximately 60 nm. As a result, the organic light emitting devices had the maximum
luminance and the luminance half-life at an initial luminance of 100 cd/m
2 shown in Table 1 (as average values of the four devices formed on one substrate).
Comparative Example 4: Production and light emitting properties of organic light emitting
device (phosphorescent device) having anode buffer layer of self-doping polyaniline
[0087] Organic light emitting devices were produced and evaluated on light emitting properties
in the same manner as Comparative Example 3 except that a light emitting layer was
formed as follows. 63.0 mg of poly(VCz-co-IrPA) synthesized in Synthesis Example 3
and 27.0 mg of polyPBD synthesized in Synthesis Example 4 were dissolved in 2, 910
mg of toluene (special grade, available from Wako Pure Chemical Industries, Ltd.),
and the resulting solution was passed through a filter with a pore size of 0.2 µm
to obtain a coating solution. The obtained coating solution was applied onto the anode
buffer layer by a spin coater at 3,000 rpm for 30 seconds, and dried at 140°C for
30 minutes to form the light emitting layer. The light emitting layer had a thickness
of approximately 80 nm. As a result, the organic light emitting devices had the maximum
luminance, the maximum external quantum efficiency, and the luminance half-life at
an initial luminance of 100 cd/m
2 shown in Table 1 as average values of the four devices formed on one substrate.
Table 1
| Examples and Comparative Examples |
Anode buffer layer |
Light emitting layer |
Maximum luminance (cd/m2) |
Maximum external quantum efficiency (%) |
Luminance half-life (hr at 100 cd/m2) |
| Example 2 |
PolySITN |
MEH-PPV |
7,200 |
2.1 |
3,900 |
| Example 3 |
PolySITN |
Poly(VCz-co-IrPA) + polyPBD |
14,700 |
5.2 |
48 |
| Comparative Example 1 |
BAYTRON CH8000 |
MEH-PPV |
4,100 |
1.4 |
1,900 |
| Comparative Example 2 |
BAYTRON CH8000 |
Poly(VCz-co-IrPA) + polyPBD |
8,300 |
3.7 |
22 |
| Comparative Example 3 |
PolySAN |
MEH-PPV |
3,800 |
1.2 |
1,800 |
| Comparative Example 4 |
PolySAN |
Poly(VCz-co-IrPA) + polyPBD |
6,500 |
3.1 |
17 |
INDUSTRIAL APPLICABILITY
[0088] By using the polymer for the anode buffer layer in the organic light emitting device
of the invention, the deterioration of the light emitting layer due to an extrinsic
dopant can be prevented, and the organic light emitting device with high light emitting
efficiency can be provided.
[0089] Further, the anode buffer layer coating solution in the organic light emitting device
of the invention has a low acidity, whereby the organic light emitting device can
be produced under reduced production load.